Railroad cross supports and process for maintenance of track bed

ABSTRACT

A cross support for a continuous rail or beam carrying moving, vibratory or other dynamic loads comprising a cross tie or sleeper adapted to be mounted on a ballast bed and having bearing areas near the top of the ballast bed bottomless troughs carrying chips and positioned so as to encompass the cross tie or sleeper adapted to feed the chips into the voids in the ballast bed when vibrated; electrically insulated elastic fasteners on each of the cross ties capable of providing permanent pressure for holding a rail or beam in an electrically insulated position on the cross tie or sleeper; as well as a process for maintaining the track bed for a railway system.

United States Patent [191 Hemmady RAILROAD CROSS SUPPORTS AND PROCESSFOR MAINTENANCE OF TRACK BED [76] Inventor: Raghuram Shripad Hemmady,

Satyabhama Nivas Vithalbhai Patel Rd., Bombay-4 Maharashtra, India [22]Filed: July 18, 1974 [21] Appl. No.1 489,520

[ Apr. 15, 1975 3,598,312 8/l97l Hamilton 238/29 Primary ExaminerLloydL. King Assistant ExaminerRandolph A. Reese Attorney, Agent, orFirml-lammond & Littell [57] ABSTRACT A cross support for a continuousrail or beam carrying moving, vibratory or other dynamic loadscomprising a cross tie or sleeper adapted to be mounted on a ballast bedand having bearing areas near the top of the ballast bed bottomlesstroughs carrying chips and positioned so as to encompass the cross tieor sleeper adapted to feed the chips into the voids in the ballast bedwhen vibrated; electrically insulated elastic fasteners on each of thecross ties capable of providing permanent pressure for holding a rail orbeam in an electrically insulated position on the cross tie or sleeper;as well as a process for maintaining the track bed for a railway system.

14 Claims, 10 Drawing Figures PATENTEBAPR 1 51975 sum 2 OF RAILROADCROSS SUPPORTS AND PROCESS FOR MAINTENANCE OF TRACK BED THE PRIOR ARTThe prior art practice of laying continuous beams such as rails orrailway or tramway tracks, which are subjected to moving loads, isusually to support the rails on cross ties/sleepers. which are in turnrested on a ballasted bed.

According to the prior art practice, the main items of track maintenanceconsist of packing or tamping the ballast bed after raising and slewingthe rails to a higher level or off to the side.

The cross ties or tie sleepers are usually made of wood, cast iron,steel reinforced or pre-stressed con crete or the like. The rails aresecured to the cross ties/- sleepers by means of rail spikes. bolts,keys or elastic fasteners and the like. whereby the gauge between therails is maintained throughout. Also the restraint against relativelongitudinal or cross-wise movement between the rails and the crosstie/sleeper is afforded by the fastening device in varying degreedepending upon the type in use. As for the tamping of ballast, manualpacking of the stone ballast under the sleeper with beater strokes isone of the oldest methods and is still prevalent in many parts of theworld. Vibratory tamping machines are used in some countries for tampingthe ballast. In a few other countries a system known as measured shovelpacking" or MSP" is also in use.

The prior art track maintenance methods in use and also the prior artengineering design of track compo nents have been evolved fromtraditional practice and they are improvements over their earlierpractices and counterparts. However they suffer severly on account oftheir inherent drawbacks. These result in (a) the ballast bed below theties/sleepers not being uniformly level and uniform in the degree ofconsolidation; and (b) in the running over the track, not beinguniformly level or smooth. resulting in rough riding and in theprogressively rapid deterioration in the running quality over the track.thereby requiring frequent attention to tracks on the one hand and arapid wearing out and deterioration of the materials of the track on theother. Vibratory machine tamping has eliminated human labor and hasbrought about a higher degree of uniformity in the condition of ballastbut even this has been found not to be up to the requisite standard.Moreover, machine tamping requires the track being occupied for longperiods of time during which no traffic can use the track. thus placinga constraint on train running operations.

The trend in railway development is taking place in two distinctdirections. Firstly in respect of freight traffic increasingly heavieraxle loads are being adopted in order to reduce the working costs aswell as operating costs and which loading consequently results in therail track being subjected to heavier duty. In the prior art trackpractices in current use, the tracks have been found not to be standingup to the increasingly heavy axle loads. Secondly, with respect topassenger services. the trend is towards higher speeds. which in turncalls for a high degree of uniformity and evenness in the railtrack'surface. The present track practices do not come up to therequisite standard. Furthermore, the increasing deterioration of qualityof rail track surfaces necessitates greater frequency of attentionrequiring occupation oftrack for longer durations, particularly in thecase of machine tamping, which becomes increasingly difficult withrising traffic densities. The requirements of modern developments inrailway operation have shown up prominently the inherent shortcomings ofthe present day track practices even in the most advanced countries.Today technologists the world over are in search of a technique of trackdesign and maintenance which will result in affording a uniform andsmooth running on track surface that will furthermore be sustainedwithout attention for long periods. The absence of a satisfactory systemof track maintenance constitutes one of the most serious problemsthreatening to thwart railway development.

In the known prior art types of track laying methods, track maintenancemethods, and ballast maintenance methods, there is a heavy ballastdeterioration and ballast erosion occurring as a result of track pumpingwith the moving loads moving on the track.

As an answer to these problems, the study in depth of the variousfunctions of the various components that comprise the rail track and theaction and interaction of the several loads and disturbing effects hasled to the evolution of this invention which seeks to overcome thevarious disadvantages and defects in the existing known types of theengineering design of track and track maintenance methods as discussedabove. Intensive research is at the back of the evolution of thisinvention which proceeds from the fundamentals of theory and which seeksto provide the ultimate solution to one the most serious problems intrack work and maintenance,

OBJECTS OF THE INVENTION The principal object of this invention is totake maximum advantage of the moving wheel loads and to utilize thisload to obtaining automatic tamping of ballast bed by providing fourbottomless troughs on outside and inside of rails and with each of saidtroughs carrying stone chips, gravels, pebbles or the like whichautomatically gravitate therefrom to fill the gaps if any, formedbetween the cross tie/sleeper and the ballast bed; the activations ofthe chips, pebbles and the like being caused by the vibrations ofdynamic loads to fill the gaps, if any, formed between the crosstie/sleeper and the ballast bed and at the same time tamping of theballast bed being caused by the weight of the loads moving on the saidrail track.

Another object of the present invention is an improvement in theevolution of the maintenance techniques and the concomitant engineeringdesign of the components comprising the tie, the chips/pebbles, troughand the fastener which take full cognizance and maximum advantage of thevarious actions and interactions taking place between the formation orsubgrade, the rail track and the moving wheel loads, which, inter alia,reduce the initial and operating costs, the overall track maintenancetime, the labor and money to the absolute minimum, and at the same timemake it possible to maintain rail track surface to a high degree ofuniformity thus affording smooth and comfortable riding of rail surfaceand slowing down the deterioration of the material from which the track,the rolling stock, and the like is constructed. These and other factorscontribute to a very large extent in reducing the overall costs ofrenewal of materials and the consumption of fuels.

An additional object of this invention is to prevent track pumping andballast erosion by providing an improved permatie" cross tie/sleeper andalso to provide a permapack" method of track maintenance.

It is further object of the present invention to provide a cross supportfor a continuous rail or beam carrying moving, vibratory or otherdynamic loads comprising permatie" cross tie or sleeper adapted to bemounted on a ballast bed and having bearing areas near the top of theballast bed; bottomless troughs carrying stone chips and the like, andpositioned so as to encompass said cross tie or sleeper adjacent to saidbearing areas and adapted to feed said stone chips and the like into theballast bed when vibrated; electrically insulated elastic fasteners oneach of said permaties capable of providing permanent pressure forholding a rail or beam is an electrically insulated position on saidcross tie or sleeper; as well as a process for maintaining the track bedfor a railway system.

These and further objects of the present invention will become apparentas the description thereof proceeds.

THE DRAWINGS The present invention will be described by reference to thefollowing drawings which are not to be deemed limitative in any mannerthereof:

FIG. 1 shows an isometric view of rails attached to a cross tie orsleeper which remains inclined at an slight angle to the horizontalballast bed;

FIG. 2 shows a front elevation ofa cross tie or sleeper when resting ona ballast bed;

FIG. 3 shows a partial top view of a cross tie or sleeper taken alongline 3-3 of FIG. 2;

FIG. 4 shows a cross-sectional view of the end portion of a cross tie orsleeper taken along line 4-4 of FIG. 2;

FIG. 5 shows a cross-section view of a substantial filled troughpositioned over a cross tie or sleeper taken along line 5-5 of FIG. 1;

FIG. 6 shows a partial cross-section view of a rail secured to a crosstie or sleeper by fasteners;

FIG. 7 shows a cross-section view of a fastener along line 77 of FIG. 6;

FIG. 8 shows a top isometric view of a trough adapted to fit over across tie or sleeper;

FIG. 9 shows an isometric view of a .l-bolt;

FIG. 10 shows a cross-section view ofa partially emptied trough of FIG.5;

DESCRIPTION OF THE INVENTION The invention relates to improvements in orrelating to cross supports for continuous beams and the like carryingmoving, or vibratory, or other dynamic loads, and the method ofmaintenance of such cross supports.

Generally speaking, this invention relates to engineering design ofcross members or cross ties for continuous beams carrying moving orvibratory or other dynamic loads, and forming foundation beds forsupporting machine tools, hydraulic presses and/or cross ties or crosssleepers which support rails carrying wheel loads as in the case ofrailway, tramways, and the like. This invention also relates to afastening device for fastening machine tool bases, rails or continuousbeams or the like to the cross supports, cross ties of cross sleepersand also to the technique or method of maintenance of such supports,cross ties or cross sleepers in particular and the rail track system asa whole. Definitions: In the specification the following expressionswherever appearing are intended to means and include the descriptionwhich follows:

tie' or sleeper are synonyms and are used to indicate the supportingcross beams or cross sleepers on which the rail rests and to which therail is also fastened. The expressions a longitudinal tie orlongitudinal sleeper may also be used. Thus the expression cross tie" ortie/sleeper" wherever used is intended to cover and include thelongitudinal tie/sleeper or cross tie/sleeper or any other form of railsupports.

Fastener The expression fastener is intended to mean and include anelastic fastener or elastic fastening used for securing the rail to thecross tie" or cross sleeper".

Trough The expression trough" is intended to mean and include arectangular shaped four sided bottomless tray fitted on a cross tie" orcross sleeper" and is adapted to hold stone chips, gravel, or pebbles orthe like.

Permapack" The method according to this invention of packing stonechips, gravel, or pebbles or the like to form a ballast bed.

Permatie A cross tie or sleeper according to this invention from teesection or a channel section with a horizontal ribbed flange providing abearing surface at the top or near the top of ballast bed.

Permagrip" An electrically insulated elastic rail fastener according tothis invention for securing a rail to permatie" cross tie or sleeper orto any other suitable type of tie.

More particularly the present invention is directed to a cross supportfor a continuous rail or beam carrying moving, vibratory or otherdynamic loads comprising a cross tie or sleeper adapted to be mounted ona ballast bed and having rail support areas adapted to support a rail orbeam; bottomless troughs carrying stone chips and the like and positionso as to encompass said cross tie or sleeper adjacent to said railsupport areas and adapted to feed said stone chips into the gaps in theballast bed when vibrated; electrically insulated elastic fasteners oneach of said rail support areas capable of providing permanent pressurefor holding a rail or beam in an electrically insulated position on saidcross tie or sleeper.

Furthermore the present invention more particularly provides a processfor maintaining the foundation bed for supporting a cross support whichin turn supports the rail or beam carrying moving, vibratory or otherdynamic loads providing a zone containing stone chips and the like oneither side of said rail or beam, said zone being slightly elevatedabove the said ballast surface and encompassing said cross support; andactivating said ballast material to flow downward into the gaps betweensaid cross support and said ballast section by the movement of saidmoving vibratory or dynamic load acting upon said rail or beam.

With these and other objects in view the invention is characterized inthat it consists of a combination (I) method of packing chips, gravel orpebbles or the like to form a ballast bed referred to as permapackmethod consisting of positioning stone chips, pebbles or the like ofpredetermined suitable sizes in such a manner that they automaticallygravitate and flow into the gaps below the tie/sleeper while beingactivated by the very moving or vibratory loads or other dynamic loadsor moving wheel loads traveling on the beams or rails.

II. A cross tie/sleeper referred to as permatie formed from the teesection or a channel section with the horizontal ribbed flangesproviding a bearing surface at the top or near the top of the ballastbed. The web or webs of said flange are provided with a pair or pairs ofbaffle plates on either side of the cross tie/sleeper preferably justbelow the rail position supported on said cross tie/- sleeper to affordanchorage and greater lateral resistance to the track, and the flange aswell as the web or webs thereof being provided with suitable bolt holesfor fixing thereto .I-bolts or other type bolts for holdingrailfasteners and lugs to keep in position said railfastener on one orboth sides of rail position supported on the said cross tie/sleeper.Moreover the cross tie/- sleeper is given suitable bends to afford thedesired upwardly inclined elevation, usually a slight elevation, at theends of the rails. At the center portion thereof. there is anacordian-like contraction with elevation of the centerline of the deviceso as to prevent center binding of cross tie/sleeper in the middle.

lll. An electrically insulated elastic fastener device referred to as apermagrip fastener consists of a clamp made from mild steel or springsteel formed by bending a flat or channel or any other structuralsection to form a C-shaped clamp, the free ends of which being extendedoutwardly to form extension arms, each carrying a hole registering withone another. The said clamp is adapted to receive therebetween one ormore similarly shaped leaf springs suitably housed inside one anotherfor further reinforcement. Extension arms of each of said leaf springsare provided with a hole adapted to register with one another and eachother and the gap formed between the extension arms of said clamp beingfilled with an insulated sandwich block carrying a hole in its centerand aligning with the corresponding holes formed in the extension armsof said leaf springs and the clamp proper for a ,l-bolt or other typebolt fitted to cross tie/sleeper to pass therethrough. The lower of saidextension arms of said clamp is provided with a pivotally mountedrectangular or square shaped shoe plate carrying an insulating sandwichsole pad adapted to rest on the rail foot for exerting the requisite toeload on the rail foot.

IV. Four rectangular shaped bottomless troughs, each carrying a pair oftransverse panels forming support members for the trough for resting onthe flange of the cross tie/sleeper and longitudinal panels thereofoverhanging the said flange of the cross tie/sleeper. Each of saidtroughs is adapted to carry stones, chips, gravel, pebbles or the likeof smaller dimenions than those normally forming the ballast bed. Eachone of said troughs is adapted to be fitted on either side of each railor the said cross tie/sleeper. With this arrangement there is theadvantage that the stone chips, gravel, pebbles or the like, loaded ineach of said troughs, flow or gravitate through corresponding openingsformed between the flange of cross tie/sleeper and the overhanging sidepanels of the trough. Furthermore vibrations or dynamic loads or movingwheel loads traveling on the said rail or continuous beams automaticallyactivate the said stone chips. gravel or the like and cause the gaps, ifany, formed in the ballast bed to get filled with said stone chips,gravel pebbles or the like. Each of said troughs is secured in positionto the flange of the cross tie/sleeper by means of suitable lugs or thelike.

According to another embodiment of this invention the permanentprecision packing technique hereinafter referred to as the permapackmethod relies on the phenomenon that it is only the heavy weight of themoving loads that brings about the actual consolidation of the ballastbed. This method according to this invention is therefore, based on thefact that in order to bring about uniformity of surface and uniformdegree of consolidation of ballast bed, what is absolutely necessary isto fill in the gaps which normally and frequently occur under the crosstie/sleeper. The method is also based on the fact that in achieving ahigh order of smoothness of running surface, it is not only necessary toensure proper cross levels and the minimum amount of twist, but alsovital that in the longitudinal direction the characteristics ofsleeper/tie support are uniform from tie to tie. In this method, thefilling up of the gaps fully and accurately is to be achieved byproviding a trough of square or rectangular shape open at top and bottomand filled with stone chips, gravel, pebbles or the like. The rest ofthe trough being formed by transverse panels forming support members forsupporting said trough on the Tee-section flange forming the cross/tiesleeper. The side plates of the trough overhanging and remainingparallel to the top flange of cross tie/sleeper form guides forpositioning for automatic discharge of and filling of gaps if any,formed between the cross tie/- sleeper and the ballast bed by the saidstone chips, gravel pebbles and the like.

According to yet another embodiment of this invention the size of thefiller material for the ballast bed or foundation bed, such as stonechips, or pebbles, to be used initially for forming a ballast bed areinitially comparatively large in the region of greater than 6 to 10 mm.These are followed by chips of intermediate sizes between 3 and 6 mm andfinally the sizes of chips may, in certain cases, be relatively small insize from less than 3 down to 2 mm. The troughs provided on either sideof each of said cross tie/sleeper are to be periodically filled withstone chips for filling the gaps formed in the ballast bed by the movingloads traveling on the rails supported on the said cross tie/sleeper.This sys tem brings about a well graded and dense mix of the ballast andconsequently imparts a high co-efficient of elasticity to the ballastbed, so desirable for a uniform running surface of rail tracks and thelike.

According to still another embodiment of this invention, the Tee-sectionor a similar section forming the cross tie/sleeper referred to aspermatie is evolved and is based on the fact that the dispersal of loadthrough the ballast bed over the top of the subgrade is best achievedwhen the point of transmission of pressure from the rail to the crosstie/sleeper is located at the highest possible level in the ballastsection-which is sought to be achieved in the case of Tee, or similarcross sectional steel cross tie/sleeper referred to as permable, wherethe flange on the T is the horizontal bearing area and is near the topof the ballast. The Tee section has the advantages in that it is aboutthe simplest and cheapest to manufacture, to handle and to lay; and itis also the strongest for withstanding the damaging effects of anyderailed wheels and can easily be reconditioned even after some damage.It has the longest service life and functionally it offers longitudinaland lateral resistance of a very high order of magnitude, a qualitywhich is so vital to the stability and satisfactory behaviour of longwelded rails adopted in modern railway or railroad tracks. Furthermore,the permatie lends itself admirably to the technique of the permapackmethod described hereinbefore of forming the uniform ballast bed.Another advantage is that it is convenient to locate the trough justabove the horizontal top flange within easy sight and access forpurposes of observation. feeding of stone chips and other attention.

According to yet another embodiment of this invention the inclinedflange area which bears on the ballast bed and that too over a narrowwidth thwarts any tendency for track pumping. The provision of two,three or more ribs on either side of said baffle plates in spaced andparallel relationship with each other and welded to the flange at thebearing area can further eliminate to a large extent any such tendencyof track pumping as distinct from the existing prior art types ofties/sleepers wherein the phenomenon of track pumping has been a majorsource of difficulty in track maintenance.

According to yet another embodiment of this invention the length of thepermatie cross tie/sleeper depends on the gauge of the railway ortramway. It can be the same as the length of cross tie/sleepers alreadyin use, a suitable length at each end of the cross tie/- sleeper beingbent upwards to correspond to the desired slanting of the rail. Thisslanting of the cross tie/- sleeper ends towards the rails induces inany derailed wheel a tendency to hug the rails and thus mitigatesagainst any dropping of wheels outside the cross tie/- sleeper ends andits serious consequences. Furthermore, the center of the crosstie/sleeper is desirably nudged upwards to prevent the same from restingdeep on the ballast bed and thus to prevent center binding giving asee-saw effect. Suitable holes are provided in the web and flange of thepermatie cross tie/sleeper to suit the location of .I-bolts or othertype of bolts required for fastening the rails to the cross tie/sleeperby means of permagrip elastic fasteners, according to this invention.The section dimensions of the cross tie/- sleeper can vary within a widerange depending on the size of rail, the gauge, the axle loads and likefactors. The web of said cross tie/sleeper is provided with baffleplates on either side of the web at right angle thereof to providedanchorage against lateral movement of the rails and thereby affordingheavy lateral track resistance, while the web of the cross tie/sleeperitself offers a heavy longitudinal resistance. Each of said baffleplates is preferably of the same width as that of the flange of thecross tie/sleeper and preferably located below the rail position restingon said cross tie/sleeper. although these baffle plates may also beprovided at any other convenient position along the length of said webof the cross tie/sleeper.

A high load carrying capacity and permanency of the pressure obtained byelasticity of the pressure transmitting media are essential featuresneeded in a good fastener for fastening cross tie/sleeper to the rail afeature which is so vital in the case of rail track formed by weldedrails. The elastic fastener hereinafter referred to as permagripfastener according to this invention embodies these qualities in asuperior manner. Besides these advantages. it also provides insulationagainst electrical conduction and against transmission of shock andvibrations between the cross tie/sleeper and the rail, which are alsothe requirements of the modern electrically signalled and high speed andheavy duty rail track respectively. Moreover, location of the bolt nearthe rail foot makes willful tampering with rail track difficult and ofleast consequence. It is also possible to adjust the rail gauge withinfine limits, and also to fix the holding down pressure accurately to apre-determined value.

The permagrip fastener according to this invention is made of mild steelor spring steel or a combination of both. The section can be either aplain strip of a structural profile of U-section, C-section or omegasection having its side webs bent outwardly to form extension lips.Alternatively the fastener clamp could be made from a mild steel channelsection bent to form omega section in shape with its free ends extendedoutwardly to form extension arms carrying a registered hole throughwhich a rail bolt is adapted to pass. Similarly shaped leaf springs eachcarrying a registered hole in its extension arms are fitted within thesaid clamp to further reinforce and provide desired elasticity for thefastener. To the bottom extension arm of said clamp is provided apivotally mounted shoe carrying an insulating sole adapted to rest onthe upper surface of rail foot and the gap formed in said two extensionarms of the clamp and the leaf springs is closed by means of aninsulating sandwich pad providing a high load bearing capacity.

The use ofa sandwich pad of compressible material. such as rubber or apad formed by interleaved layers of rubber and cord or like synthetic ornatural compressible material, as a pad fitted between the two extensionarms of the fastener clamp or the fastener itself enables heavy loads tobe carried without straining the steel beyond the desired limited. Theprovision of a pivotally mounted shoe pad also made from sheet metalhinged to the lower of the extension arms of said fastener itself bearsfully on the upper surface of the rail foot no matter what thedeflection and load on the fastener proper may be. The said shoe pad isfurther insulated by means of an interleaved sandwich sole also madefrom the same or similar material as the said sandwich pad, and thisalso provides electrical insulation, and the desired capacity to absorbvibrations and shocks and to prevent the same from being transferred bythe rail to the fastener proper and vice versa.

The rail foot is also provided with a rail pad underneath made frominterleaved layers of rubber and cord or other compressible material soas to form a cushion between the flange of cross tie/sleeper and therail foot, thereby insulating the rail from conduction of electricityand from vibrations and shocks.

Thus this invention as referred to a permatrak relates to (i) thetechnique of rail track maintenance referred to as permapack, (ii) theengineering design of a permatie cross tie/sleeper, (iii) the permagripfastener, (iv) the apparatus for automatically and precisely filling thegaps formed between ballast bed and the cross tie/sleeper, (v) permatiecross tie/sleeper, (vi) the provision for electrical insulation betweenthe rail and the fastener provides technologically the long sought aftersatisfactory solution to the one of most serious problems of trackmaintenance in the context of the increasingly heavy axle loads,increasing speeds, with the least amount of time and labor required fortrack maintenance. Moreover this invention also seeks to bring aboutvast reductions in the working expenses and renewal costs.

It is to be understood that any of the components described and claimedherein can be used independently or collectively on existing tracks andit is not necessary to alter the entire track structure to derive thebenefits resulting from the invention.

The invention will now be described with reference to the accompanyingdrawings in which like reference numerals represent like parts. In FIGS.1 and 2 the permatie cross tie/sleeper 2 is formed from a Tee-sectionhaving a flange 3 and a web 4 for said flange formed in the bottomcenter of said flange 3. One free end 5 of said Tee-section extendingalong one plane is bent at 6 and is extended upwardly to form a V'inshape; and the midportion of said extension is bent upwards at 7 to forman inverted V-shape in the middle. The extension is bent at 8 and isextended upwardly along one plane to form the other free end 9 to formanother V-in shape. Said cross tie/sleeper in its front elevationsubstantially resembles a wide angle W in shape when seen from theflange end 3 as shown in FIG. 2. Elements 10 are baffle plates welded toor otherwise formed integral with the web 4 on either side thereof andpreferably below the rail position to afford anchorage and greaterlateral resistance to the track. A series of two, three or more ribs 11are welded to or otherwise formed integral with the underside of theflange 3 on either side of said baffles 11 respectively in spaced andparallel relationship with each other to counteract the phenomenon oftrack pumping. The flange 3 as well as the web 4 are provided withsuitable bolt holes 12 on the flange and 13 on the web for fixingthereto .I-type bolts 14 (shown in FIG. 9) for holding the rail fasteneron one or both sides of rail position supported to said permatie crosstie/sleeper.

The trough 1 is shown in FIGS. 1. 5, 8 and 10 for automatic feeding ofballast such as stone chips. gravel and the like is adapted to be fittedto the flange 3 of permatie cross tie/sleeper 2 on either side of railposition adjacent the permagrip elastic rail fastener shown in FIG. 6.Troughs I are placed over rectangular free ends 5 and 9 respectively ofsaid cross tie/sleeper 2 (particularly as shown in FIG. 1). Each trough1 consists of a rectangular shaped bottomless tray with transversevertical plates resting on the flange of the cross tie/sleeper and thetwo side walls thereof are extended downwards to form extension members15 forming a guide for holding and automatically dropping the stonepebbles, chips or gravel loaded in said trough into the gaps formedbetween the ballast bed and the permatie cross tie/sleeper 2 as a resultof the vibration and shocks transmitted to the cross tie/sleeper fromthe moving wheel loads on the rails mounted on said permatie crossties/sleepers 2.

The permagrip fasteners 16 (particularly as shown in FIG. 6) consists ofcasing 17 formed by bending a channel or omega shaped channel or thelike to resemble a C in shape. The free ends of this fastener areextended along one plane to form upper and lower extension arms 18 and19 in parallel relationship with one another and carrying a registeredhole 20 through which a J-type bolt 14 is adapted to pass. Said channelsection has lateral extension lips 21 formed on either side of saidsection. Said casing 17 is adapted to receive there between one or moresimilarly shaped leaf springs 32, 33. and 34 and with each carrying ahole 20 in its respective extension arms and registering with each otherso that said bolt 14 can pass therethrough. The lower extension arm 19is provided with a pivotally mounted shoe pad or plate 22 mounted on oneor two pivots 23. In another embodiment (not shown) shoe plate 22 ismuch wider than that shown in FIG. 6 has a hole in its center so as tofit within the gap formed between the opening formed in said permagripelastic fastener 16 between said two extension arms 18 and 19 in such amanner that this hole is registered with the said register hole 20formed in the staggered leaf springs and the two extension arms 18 and19 so that a bolt 14 can be passed therethrough for securing thepermagrip fastener 16 to a permatie cross tie/sleeper 2. The said shoepad 22 is also provided with an electrically insulated sole 24.

The following describes the manner in which the permatie crosstie/sleeper 2 is laid and maintained according to this invention, on theballast bed.

The ballast bed 25 is first prepared in a conventional manner withbroken stone or other ballast. Then a series of permatie crosstie/sleeprs 2 are laid in such a way that the bent webs 4 rest on theballast bed in spaced and parallel relationship with one another andlaid in such a way that the webs 4 rest on the ballast bed. Then a pairof rails 26 as shown in FIGS. 1 and 6 are laid longitudinally on asupporting sandwich pad 27 rested on flange 3. Then the permagripelastic rail fastener is fitted to the J-type bolt 14 so that the shoeplate 22 with the attached insulating sole 24 rest on the upper surfaceof foot 28 of rail 26. This combination is secured thereto by means of anut 29 fitted to said rail bolt 14. and the toe load on the rail 26 isthen finely adjusted by tightening or loosening the nut 29 on rail bolt14 so as to give the desired pressure. The permatie cross tie/sleeperare packed underneath to the desired level with the normal size stoneballast. Then a pair of troughs 1--1 are placed on the web 3 of each ofsaid series of permatie cross tie/sleepers 2 on the outside and insideof each of said rails 26 mounted on said permatie cross tie/sleeper 2.The troughs are mounted outside the permagrip elastic rail fastener 16and each of said troughs is filled with stone chips and/or ballast.initially with larger and later with smaller sizes with each successiveloading of said troughs. This enables the gaps formed between theballast bed and the permatie cross tie/sleepers 2, under moving trafficwheel loads to be automatically filled with ballast from each of saidtroughs l, which ballast is dropped via the openings formed on eitherside of the overhanging sides of said troughs 1. The arrangement is suchthat the rails 26 laid on permatie cross tie/sleeper are positioned atan angle inclined to the horizontal line formed by the ballast bed(particularly as shown in FIG. 1). According to this invention wheneverlevels of rail go out and require readjustment, the rail which is low isjacked up and the chips/pebbles and the like induced to work in to thegap below the permatie by tapping the trough, by piercing the mass ofchips or pebbles and the like with a wire/spoke and/or similar means;and finally automatic packing with the chips or gravel takes place dueto the moving traffic loads on the said rails.

According to this invention the permagrip elastic rail fasteners 16 maybe fitted alternately on the rails at the rate of one per rail seatinstead of two thereby effecting saving in costs of the fastenerswithout jeopardizing the stiffness of the track assembly and theanchorage against rail creep.

According to an embodiment of invention, when the ballast bed is new,the stone chips or gravel 30 packed in the troughs 1 are initiallylarger in sizes. With the moving wheel loads of the trains moving on therails and with the consequent vibrations caused to the permatie sleepersthe stone chips or gravel are induced to drop via the openings formedbetween the two overhanging side panels 15 and the flange 3 of saidpermatie cross tie/sleeper to fill the gaps formed in said ballast bed.Once these gaps have been filled. further tamping of the ballast bed isdone automatically by the vibrations transmitted by the permatie crosstie/sleeper caused by the moving loads of trains moving on the railssupported on these permatie cross ties/sleepers. Initially these troughspreferably should be inspected and filled to the top with stone chips orgravel at intervals of between 3 days to 7 days. FIG. shows a crosssection view of a substantially filled trough positioned over a crosstie/sleeper. FIG. 10 shows a cross-section view of a partially emptiedtrough. Thereafter filing to the top of the troughs may be carried outat intervals of 3-4 weeks and the size of stone chips or gravel and theamount thereof reduced progressively. Thereafter the ballast bed willsettle down; and periodical toppingup of the troughs may have to be doneat intervals of 6 months. At this time the size of stone chips or gravelcan be further reduced. Thereafter it will be found that generally thereis no further looseness in the ballast bed to cause any gaps in theballast bed. This bed is substantially settled down and the level ofstone chips or gravel in the said troughs remains almost constant. Thusautomatic filling of the ballast bed is then obtained by the permapakmathod of track maintenance.

According to one embodiment, the permagrip elastic fastener is formedfrom inverted omega shaped channel section made from spring steelsubstantially resembling the fastener 16 shown in FIG. 6 and carrying ahole in each of its extension arms registering with one another andthrough which a J-type or similar bolt 14 is adapted to pass. The lowerarm 19 of said extension arms is provided a pivotally mounted shoe plate22 carrying a shoe pad 24. There is a sandwich block 31 positionedwithin the gap formed in said extension arms 18 and 19 of the fastenerand said sandwich block also carries a hole 20 registering with the saidhole 20 formed in the said extension arms for passing therethrough, aJ-type bolt 14.

According to yet another embodiment of this invention the permagripelastic fastener 16 is formed from a series of leaf springs 32, 33 and34 slid within one another and each of said springs bent in the form ofa C shape. The free ends thereof are extended outwardly to formextension arms carrying a hole 20 for passing therethrough a J-type bolt14. At the bottom or the lower extension arm 19 is provided a pivotallymounted shoe plate 22 mounted on pivot 23, and a shoe pad 24 providedfor said shoe plate. A sandwich block 31 carrying a hole 20 is fittedwithin the gap formed in said extension arms of the fastener so thatsaid hole 20 of said sandwich block registers with the correspondinghole 20 formed in said extension arm for passing therethrough a J-typebolt 14.

According to a further embodiment of this invention the permagripelastic fastener 16 is formed from a U- shaped (not shown) spring steelbent to form C-in shape. The free ends thereof are extended outwardly toform extension arms carrying a hole 20 near its free end and to thebottom of the lower extension arm 19 is provided a shoe plate 22 mountedon pivot 23 and a shoe pad 24 is provided for said shoe plate 22, and asandwich block 31 carrying a hole 20 is fitted within the gap formedbetween said two extension arms so that hole 20 of the sandwich padregisters with the corresponding holes 20 formed in said extension armsof the fastener for passing therethrough a J-type bolt 14.

According to a further embodiment of this invention the permagripelastic fastener 16 is formed from a mild steel U-channel section (notshown) bent to a C-shape and the free ends of which are extended to formextension arms each carrying a hole 20. Each arm is comprised by two ormore similarly shaped leaf springs. The other features of the fastener16 are analogous to those described above.

FIG. 7 shows a cross-section view of a permagrip fastener 16 along line7-7 of FIG. 6. The permagrip fastener is held together by means of athreaded .l-bolt 14 having nut 29 tightened thereon. The casing 17 shownin a partial cut-away-section has lateral extension lips 21 which arealso shown in a partial cut-away-section. The lateral extension lipsencase and compress therebetween a sandwich block 31 which consists ofthree layers. However there could be more or less layers than thesethree layers in sandwich block 31 as long as there is at least onelayer. The lateral extension lips in combination with the casing 17encase and compress therebetween the three leaf springs 32, 33 and 34.The number of these leaf springs may be increased or decreased, providedthere is at least one leaf spring. All of these elements of thepermagrip fastener have an opening therein which can be aligned to formthe continuous passageway 20 through which the .l-bolt 14 is inserted.

According to another embodiment of this invention the permagrip elasticrail fastener 16 is formed from an omega shaped channel section (notshown) made from spring steel bent into a C-shape. The other features ofthe fastener 16 are analogous to those described above.

According to another embodiment of this invention the permatie crosstie/sleeper 2 is formed from a T- section extending along one plane. Theflange 3 carries four holes near its free ends 5 and 9. The web 4 isprovided with baffles 10 preferably below the rail position on eitherside of said web 4. Ribs 11 are provided on the bearing surface of theflange 3 which also carries holes 12 at right angle to correspondingholes 13 formed in said flange 3. This enables a J-type or similar boltto be passed therethrough for securing permagrip elastic rail fastener16 to said permatie cross tie/sleeper 2 for securing rails 26 topermatie cross tie/sleeper as shown in FIG. 6. A series of ribs 11 arewelded to the underside of flange 3 on either side of baffle plates 10respectively in spaced and parallel relationship with one another.

According to a further embodiment of this invention the permatie crossite/sleeper 2 is formed form a T- section formed from a flange 3 and aweb 4 and carrying two bent extension arms 35 and 36 extending upwardlyfrom the middle portion thereof. The other features of the crosstie/sleeper are analogous to those described above.

According to a further embodiment of this invention the permatie crosstie/sleeper 2 is formed from a U- or C-channel section (not shown)having a flange and two webs and the free ends of said channel sectionbeing bent upwardly at an angle inclined to the horizontal line formedby the middle portion thereof which extends along one plane. A baffleplate is welded within the gap formed between the two webs and the webscarry a hole. This hole is respectively at a right angle to thecorresponding holes formed in the flange on either side of said baffleand so that a J-type bolt can be passed therethrough for securingpermagrip elastic rail fasteners for anchoring rails to the crosstie/sleeper substantially as described hereinbefore. Ribs are welded tounderside of the flange on either side of baffles respectively in spacedand parallel relationship with each other Although the present inventionhas been disclosed in connection with a few preferred embodimentsthereof, variations and modifications may be resorted to by thoseskilled in the art without departing from the principles of the newinvention. All of these variations and modifications are considered tobe within the true spirit and scope of the present invention asdisclosed in the foregoing description and defined by the appendedclaims.

I claim:

I. A cross support for a continuous rail or beam carrying moving,vibratory or other dynamic loads comprising a cross tie or sleeperadapted to be mounted on a ballast bed and having bearing areas near thetop of said ballast bed; bottomless troughs carrying stone chips and thelike and positioned so as to encompass said cross tie or sleeperadjacent to said bearing areas and adapted to feed said chips into thegaps in said ballast bed when vibrated; electrically insulated elasticfasteners on each of said bearing areas capable of providing permanentpressure for holding a rail or beam in an electrically insulatedposition on said cross tie or sleeper.

2. The cross support of claim I, wherein said cross tie or sleeper isconstructed with a T-cross section having a flange at the top portionthereof and a web at the lower portion thereof: at least one baffleplate integral with said web to anchor said web and to provide greaterlateral resistance to the web said web being inclined to horizontal; andat least one rib integral with the underside of said flange so as tocounteract the phenomenon of track pumping.

3. The cross support of claim 2, wherein said cross tie or sleeper has aflange and a web. each having holes therein which are located such thata J-bolt can be passed through one hole in the flange and through thecorresponding hole in the web.

4. The cross support of claim 2, wherein said cross tie or sleeper hasouter arms which are raised at the free end thereof; said bottomlesstroughs resting on said cross tie or sleeper on either side of saidbearing areas with said fasteners positioned between said bottomlesstrough and said bearing areas; wherein said ballast flows into any gapsformed under the said flange of said cross tie or sleeper providingautomatic and accurate maintenance thereof.

5. The cross support of claim 1, wherein said cross tie or sleeper isbent into a slight W shape and having inner arms and outer arms; saidrail or beam adapted to be fastened onto said bearing area located onthe outer arms of said cross tie or sleeper; whereby the said slight Wshape of said cross tie or sleeper provides an inclined bent shapeaffording increased anchorage and lateral resistance to said cross tieor sleeper and also counteracts pumping; whereby in the case of aderailment the derailed wheel tends to hug the rails thereby preventingthe wheel from falling outside the cross tie or sleeper.

6. The cross support of claim 1, wherein said electrically insulatingelastic fasteners are positioned between said bottomless troughs andsaid bearing areas.

7. The cross support of claim 1, wherein said bottomless troughscontains larger gravel in the initial stages thereof and progressivelysmaller gravel in the later stages.

8. The cross support of claim 1, wherein said electrically insulatedelastic fastener is shaped like a clamp having a hole in the uppersurface and a hole in the lower surface in which is housed at least oneleaf spring with a hole therein registered with and aligned with theholes in said clamp; said at least one leaf spring and said clamp beingarranged such that there is a gap between the inner edges of said atleast one leaf spring; and an insulated sandwich block positioned insaid gap and having a hole therethrough aligned with said holes in saidclamp and said at least one leaf spring; a J-bolt passing through saidaligned holes for affixing said fastener to said cross tie or sleeper.

9. The cross support of claim 8, wherein said fastener clamp hasextended arms adapted to firmly hold the foot portion of a rail or beamwhen said clamp bolt is tightened; and a pad of electrically insulatedelastic material adapted to be placed between said extended arms of saidclamp and said foot portion.

10. A process for maintaining the ballast foundation bed for supportinga cross support which in turn supports rail or beam carrying moving.vibratory or other dynamic loads comprising providing a zone containingstone chips and the like on either side of said rail or beam; said zonebeing suitably elevated above said ballast foundation bed andencompassing said cross support; and activating said stone chips and thelike to flow downward into the gaps between said cross support and saidballast foundation bed by the movement of said moving vibratory ordynamic load acting upon said rail or beam.

11. The process of claim 10, wherein said foundation bed is a railroadballast bed, and wherein said moving vibratory dynamic load is supportedby a continuous rail.

12. The process of claim 11, wherein said stone chips and the like isinitially comparatively large sized, then followed by chips and the likeof intermediate size, and finally followed by chips and the likerelatively small in size.

13. The process of claim 12, wherein said comparatively large size chipsis from greater than 6 to 10 mm, said intermediate size chips is from 3to 6 mm, and said relatively small size chips is less than 3 down to 2mm.

14. In a process for repairing local irregularity, improving ormaintaining a railroad track system comprising a ballast bed above whichis positioned a cross support which supports a continuous rail carryingmoving, vibratory or other dynamic loads, and utilizing a process tofill in the gaps between said cross support and said ballast bed; theimprovement which comprises utilizing the process of claim 10 to fill inthe gaps between said cross support and said ballast bed.

1. A cross support for a continuous rail or beam carrying moving,vibratory or other dynamic loads comprising a cross tie or sleeperadapted to be mounted on a ballast bed and having bearing areas near thetop of said ballast bed; bottomless troughs carrying stone chips and thelike and positioned so as to encompass said cross tie or sleeperadjacent to said bearing areas and adapted to feed said chips into thegaps in said ballast bed when vibrated; electrically insulated elasticfasteners on each of said bearing areas capable of providing permanentpressure for holding a rail or beam in an electrically insulatedposition on said cross tie or sleeper.
 2. The cross support of claim 1,wherein said cross tie or sleeper is constructed with a T-cross sectionhaving a flange at the top portion thereof and a web at the lowerportion thereof; at least one baffle plate integral with said web toanchor said web and to provide greater lateral resistance to the websaid web being inclined to horizontal; and at least one rib integralwith the underside of said flange so as to counteract the phenomenon oftrack pumping.
 3. The cross support of claim 2, wherein said cross tieor sleeper has a flange and a web, each having holes therein which arelocated such that a J-bolt can be passed through one hole in the flangeand through the corresponding hole in the web.
 4. The cross support ofclaim 2, wherein said cross tie or sleeper has outer arms which areraised at the free end thereof; said bottomless troughs resting on saidcross tie or sleeper on either side of said bearing areas with saidfasteners positioned between said bottomless trough and said bearingareas; wherein said ballast flows into any gaps formed under the saidflange of said cross tie or sleeper providing automatic and accuratemaintenance thereof.
 5. The cross support of claim 1, wherein said crosstie or sleeper is bent into a slight W shape and having inner arms andouter arms; said rail or beam adapted to be fastened onto said bearingarea located on the outer arms of said cross tie or sleeper; whereby thesaid slight W shape of said cross tie or sleeper provides an inclinedbent shape affording increased anchorage and lateral resistance to saidcross tie or sleeper and also counteracts pumping; whereby in the caseof a derailment the derailed wheel tends to hug the rails therebypreventing the wheel from falling outside the cross tie or sleeper. 6.The cross support of claim 1, wherein said electrically insulatingelastic fasteners are positioned between said bottomless troughs andsaid bearing areas.
 7. The cross support of claim 1, wherein saidbottomless troughs contains larger gravel in the initial stages thereofand progressively smaller gravel in the later stages.
 8. The crosssupport of claim 1, wherein said electrically insulated elastic fasteneris shaped like a clamp having a hole in the upper surface and a hole inthe lower surface in which is housed at least one leaf spring with ahole therein registered with and aligned with the holes in said clamp;said at least one leaf spring and said clamp being arranged such thatthere is a gap between the inner edges of saiD at least one leaf spring;and an insulated sandwich block positioned in said gap and having a holetherethrough aligned with said holes in said clamp and said at least oneleaf spring; a J-bolt passing through said aligned holes for affixingsaid fastener to said cross tie or sleeper.
 9. The cross support ofclaim 8, wherein said fastener clamp has extended arms adapted to firmlyhold the foot portion of a rail or beam when said clamp bolt istightened; and a pad of electrically insulated elastic material adaptedto be placed between said extended arms of said clamp and said footportion.
 10. A process for maintaining the ballast foundation bed forsupporting a cross support which in turn supports rail or beam carryingmoving, vibratory or other dynamic loads comprising providing a zonecontaining stone chips and the like on either side of said rail or beam,said zone being suitably elevated above said ballast foundation bed andencompassing said cross support; and activating said stone chips and thelike to flow downward into the gaps between said cross support and saidballast foundation bed by the movement of said moving vibratory ordynamic load acting upon said rail or beam.
 11. The process of claim 10,wherein said foundation bed is a railroad ballast bed, and wherein saidmoving vibratory dynamic load is supported by a continuous rail.
 12. Theprocess of claim 11, wherein said stone chips and the like is initiallycomparatively large sized, then followed by chips and the like ofintermediate size, and finally followed by chips and the like relativelysmall in size.
 13. The process of claim 12, wherein said comparativelylarge size chips is from greater than 6 to 10 mm, said intermediate sizechips is from 3 to 6 mm, and said relatively small size chips is lessthan 3 down to 2 mm.
 14. In a process for repairing local irregularity,improving or maintaining a railroad track system comprising a ballastbed above which is positioned a cross support which supports acontinuous rail carrying moving, vibratory or other dynamic loads, andutilizing a process to fill in the gaps between said cross support andsaid ballast bed; the improvement which comprises utilizing the processof claim 10 to fill in the gaps between said cross support and saidballast bed.